System and method for tracking an item on a pallet in a warehouse

ABSTRACT

A system and method for tracking an item on a pallet in a warehouse is provided. The system includes at least one pallet, designated storage locations in the warehouse, a vehicle for lifting, moving, and setting down pallets, a motion sensor, an image processor, a server, and an algorithm. The motion sensor and the image processer are provided on the vehicle. Both the motion sensor and the image processor are wireless enabled. The motion sensor is capable of determining the lifting, moving and setting down of pallets, and is configured to send lifting, moving, and setting down information when the motion sensor senses motion to the algorithm. The image processor is provided with a field of view capable of processing images of the pallet and the location of the pallet when the pallet is in contact with the vehicle.

FIELD OF THE INVENTION

The present invention relates to a system and method of tracking items on pallets in warehouse, and in particular to a method and system for tracking pallets using information about the pallets location in conjunction with an algorithm.

BACKGROUND

Generally speaking, a warehouse can lose significant amounts of money because of errors in storing items on pallets. This causes problems with replenishment workflows. The main problems for losses in these workflows are pallets lost due to storage at incorrect slot locations and “twilight zone” problems, that is pallets being stored randomly and not in designated storage slots. In either case, the locations of items on pallets in the warehouse are unknown.

In one aspect of the problem, pallets may be placed in an incorrect slot location due to misidentification. Identifying tags on the pallets, which may be labels, barcodes, alphanumeric codes or the like, are usually close to ground level on the pallet. The forklift operator may misread the identifying tag because of its location and therefore mistakenly put a pallet into slot A when the tag indicates the pallet belongs in slot B. At a later time a forklift operator may have a new pallet designated for slot B. Because slot B is already occupied, the forklift operator drops the pallet in the twilight zone to save time, instead of relocating the pallets to their proper slots. This creates an additional problem, now two pallets are lost.

In another scenario, there are two adjacent slots. Slot A is occupied with the pallet designated for slot B. The forklift operator sees one empty slot (slot B) in close proximity to where his new pallet is designated (slot A) and mistakenly puts the new pallet in the wrong slot. Even though the two pallets are close to their designated storage slots, both become lost in the system.

In a further scenario, the forklift operator may incorrectly record which slot he has put a pallet.

In another scenario, forklift operators working on productivity incentives may put away pallets far from the picking location in order to improve their productivity, ultimately resulting in long travel times when retrieving the pallets.

When pallets are deposited in the “twilight zone,” pallets are lost due to disorganization. Pallets in this zone may go past expiration dates or be lost to shipping deadlines. These pallets may have to be written off as a loss to the owner as their whereabouts are unknown. Even if a pallet is not lost, but is located in the “twilight zone,” productivity suffers as the pallet retrieval is more complicated and may pose longer travel to shelf.

Many warehouses have computer assisted warehouse management systems (WMS). A WMS may require a forklift operator to scan the pallet identifying tag with a handheld barcode reader and record pallet location with the reader. This information is sent to a WMS terminal. However, human error in entering data or placing the pallet gives the WMS incorrect information, resulting in lost pallets.

Some WMS computer terminals are mounted on the forklift itself. A driver may have to slow down when reading data on the terminal or be distracted in driving the forklift, possibly causing an accident. Both scenarios limit productivity.

Therefore, a need exists for a warehouse management system for tracking pallet storage which overcomes the problems discussed hereinbefore.

SUMMARY

Accordingly, in one aspect, the present invention embraces a system for tracking an item on a pallet in a warehouse.

In an exemplary embodiment, the system for tracking an item on a pallet in a warehouse includes, at least one pallet; designated storage locations in the warehouse; and a vehicle for lifting, moving, and setting down pallets. The system further includes a motion sensor. The motion sensor is provided on the vehicle. The motion sensor is wireless enabled and capable of determining the lifting, moving and setting down of pallets. The motion sensor is configured to send lifting, moving, and setting down information when the motion sensor senses motion. The system further includes an image processor provided on the vehicle. The image processor is wireless enabled and has a field of view capable of processing images of the pallet and the location of the pallet when the pallet is in contact with or in direct line of sight of the vehicle. The system also includes a server. The server is communicatively linked to the image processor and the motion sensor. The server has access to a database. The system further includes an algorithm. The algorithm is communicatively linked to the motion sensor, the image processor, and the server. The algorithm is configured to direct the image processor to process images based on information received from the motion sensor about the pallet being lifted, being moved, and being set down. The algorithm is further configured to receive processed images and to send the processed images with annotated motion sensor information to the server. The server is configured to organize the annotated processed images. The server is further configured to identify and flag annotated processed images which show pallets without identifying tags and pallets which are not set down in designated storage locations. It is to be understood in the context of the invention that image processing includes both capturing an image and processing the image.

In another exemplary embodiment of the system, the vehicle is a forklift truck.

In another exemplary embodiment of the system, the image processor and the motion sensor are one unit.

In another exemplary embodiment of the system, the one unit is a smartphone.

In another exemplary embodiment of the system, the one unit is ruggedized.

In yet another exemplary embodiment of the system, the designated locations are slot positions sized to fit a pallet and are identifiable by slot numbers.

In another exemplary embodiment of the system, the algorithm is configured to instruct the image processor to process an image when the motion sensor senses a pallet is lifted, moved, or set down.

In another exemplary embodiment of the system, the annotations are information about the pallet being lifted or being set down when the image was processed.

In yet another exemplary embodiment of the system, the server is configured to send the organized annotated processed images and any flags of annotated processed images to the database.

In another exemplary embodiment, the system further comprises means to convert the organized annotated processed images and any flags of annotated processed images in the database into spreadsheet format.

In yet another exemplary embodiment of the system, the pallet has an identifying tag.

In another exemplary embodiment of the system, the identifying tag is a barcode.

In another exemplary embodiment of the system, the image processor is provided with barcode scanning and decoding capability; and the image processor is configured to scan and decode barcodes on the pallet and to send the decoded barcode to the algorithm with the processed image.

In yet another exemplary embodiment of the system, the identifying tag is an alphanumeric code.

In another embodiment of the system, the image processor is configured to read and decode alphanumeric codes on the pallet and is configured to send decoded alphanumeric codes to the algorithm with the processed image.

In another exemplary embodiment of the system, the algorithm is configured to read and decode alphanumeric codes on the pallet in the processed images, and the algorithm is configured to send decoded alphanumeric codes to the server with the processed images.

In another exemplary embodiment of the system, the algorithm is part of the server.

In another aspect, the present invention embraces a method of tracking an item on a pallet in a warehouse.

In an exemplary embodiment, the method comprises the steps of: selecting a pallet at a first location in the warehouse for movement; lifting the pallet with a vehicle for lifting, moving and setting down; taking an image of the pallet and pick-up location; sending the image of the pallet and first location with information that the pallet is being lifted to a server; moving the pallet to a second location in the warehouse; setting down the pallet in the second location; taking an image of the pallet and the second location; sending the image of the pallet and the second location with information that the pallet is being set down to a server; determining if the pallet has an identifying tag from the image of the pallet; determining if the second location is a designated storage location; identifying the pallet as an anomaly if the pallet has no identifying tag; identifying the pallet as an anomaly if the second location is not a designated storage location; and storing the pallet image, location, pick-up and set-down information in a database.

In another exemplary embodiment of the method, the vehicle is a fork lift truck, and the lifting step, the moving step, and the setting down step are accomplished with the fork lift truck.

In another exemplary embodiment of the method, the vehicle is provided with an image processor and a motion sensor. The image processor and motion sensor are communicatively linked to a first algorithm. The first algorithm is configured to direct the image processor to process images when the motion sensor indicates that the pallet is being lifted or set-down. The method further comprising the steps of: sensing the lifting of the pallet with the motion sensor simultaneously with the lifting step; communicating the lifting to the first algorithm; directing the image processor to process an image of the pallet and the first location before the first taking step; sensing the setting down of the pallet with the motion sensor simultaneously with the setting down step; communicating the setting down to the first algorithm; and directing the image processor to process an image of the pallet and the second location before the second taking step.

In another exemplary embodiment of the method, the determining steps and the identifying steps are accomplished by a second algorithm in the server.

In yet another exemplary embodiment, the method further comprises the step of converting the pallet image information and location into a spreadsheet in the database.

In another exemplary embodiment, the method further comprises the step of repeating the preceding steps every time the pallet is moved.

In another exemplary embodiment of the method, the identifying tag is a barcode. The image processor is provided with barcode scanning and decoding capability. The method further comprising the step of scanning the barcode; and wherein the first and second sending steps include sending the scanned barcode information to the server.

In another exemplary embodiment of the method, the identifying tag is an alphanumeric code. The image processor is provided with alphanumeric code decoding capability. The method further comprising the step of scanning and decoding the alphanumeric code; and wherein the first and second sending steps include sending the decoded alphanumeric code to the server.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts the hardware portion of one embodiment of the system for tracking an item on a pallet in a warehouse in accordance with the present invention.

FIG. 2 graphically depicts a flowchart of the working of the system with input actions to the algorithm and the algorithm response in accordance with an embodiment of the present invention.

FIGS. 3A and 3B graphically depict a flowchart of one embodiment of the method of tracking an item on a pallet in a warehouse in accordance with the present invention.

DETAILED DESCRIPTION

The present invention embraces a system for tracking an item on a pallet in a warehouse. Referring to FIGS. 1 and 2, which depict different aspects of the system according to one embodiment of the invention.

In an exemplary embodiment, as depicted in FIG. 1, which generally depicts the warehouse (20), the system is comprised of at least one pallet (24), designated storage locations (26) in the warehouse (20), a vehicle (22) for lifting, moving, and setting down pallets, a motion sensor (34) provided on the vehicle (22), an image processor (32) provided on the vehicle (22), a server (36) which is wirelessly and communicatively linked to the motion sensor (34) and the image processer (32). The system also comprises an algorithm (50) which may or may not be part of the server (36). The algorithm is shown here as part of the server (36). The algorithm (50) is detailed in FIG. 2. The motion sensor (34) is wireless enabled and is capable of determining the lifting, moving and setting down of pallets. The motion sensor (34) is configured to send lifting, moving, and setting down information when the motion sensor (34) senses motion. The image processor (32) is wireless enabled and has a field of view capable of processing images of the pallet (24) and the location of the pallet (24) when the pallet (24) is in contact with the vehicle (22) or when the pallet (24) is in direct line-of-sight of the vehicle (22). The image processor (32) is configured to send processed images to the algorithm (50). Non-designated storage locations (28) for pallets are any locations which are not marked with slot numbers (27). It is to be understood in the context of the invention that image processing includes both capturing an image and processing the image.

In another exemplary embodiment, the vehicle (22) is a forklift truck.

In another exemplary embodiment, the image processor (32) and the motion sensor (34) are one unit.

In another exemplary embodiment, the one unit is a smartphone. As is known in the art, most smart phones include accelerometers which can distinguish motion.

In another exemplary embodiment, the one unit is ruggedized. The one unit could be a ruggedized industrial device or be ruggedized custom built hardware.

In another exemplary embodiment, the designated storage locations (26) are identifiable slot positions sized to fit a pallet (24) and identifiable by slot numbers (27). The slot numbers (27) may be alphanumeric as shown. Additionally, the slot positions (26) may be more than one level high. The slot numbers (27) shown are just one example of a typical designation.

In yet another exemplary embodiment, the pallet (24) is provided with and identifying tag (30).

In another exemplary embodiment, the identifying tag (30) is a barcode (30) as shown in the FIG. 1.

In another exemplary embodiment, the image processor (32) is provided with barcode scanning and decoding software and is configured to scan and decode barcodes (30) on the pallet (24) and to send decoded barcode information to the algorithm with processed images.

In yet another exemplary embodiment, the identifying tag (30) is an alphanumeric code (not shown).

In another exemplary embodiment, the image processor (32) is configured to read and decode alphanumeric codes on the pallet (24) and is configured to send decoded alphanumeric codes to the algorithm with the processed image.

Referring now to FIG. 2 in conjunction with the hardware depicted in FIG. 1, in an exemplary embodiment of the invention, the system comprises an algorithm (50) which is communicatively linked to the motion sensor (34), the image processor (32) and the server (36). The algorithm (50) is configured to direct the image processor (32) to process images based on information received from the motion sensor (34) about the pallet (24) being lifted, moved and being set down. The algorithm (50) is further configured to receive processed images from the image processor (32) and to send the processed images with annotated motion sensor (34) information to the server (36). The server (36) is configured to organize the annotated processed images and is configured to identify and flag annotated processed images which show pallets without identifying tags and pallets which are not set down in designated storage locations (26).

In FIG. 2 the system is shown as a series of actions (60) which trigger a series of responses from the algorithm (50). Thus action (61) is the motion sensor sensing a pallet being lifted and sending the lifting information to the algorithm (50). The algorithm (50) receives the information from the motion sensor which triggers algorithm response (51), that is, the algorithm (50) recognizes the pallet (24) is being lifted from the data received from the motion sensor (34). For example a positive motion value may designate lifting, while a negative value may designate setting down. The algorithm (50) recognizes the lifting action and directs the image processor (32) to process an image of the pallet (24) and location of the lifting. In action (62), the image processor (32) takes an image of the pallet (24) and location. Preferably, the image processor (32) will also scan and decodes any identifying tag (30) information on the pallet (24). This information is sent back to the algorithm (50) in action (63). The information triggers algorithm (50) response (52) wherein the algorithm (50) sends the processed image and location and any identifying tag information to the server (36) with an annotation that the processed image and location was taken when the pallet (24) was lifted. When the pallet (24) is set down, in action (64), the motion sensor (34) senses the pallet (24) being set down and sends this information to the algorithm (50). This information triggers algorithm response (53) directing the image processor (32) to take an image of the pallet (24) and location. In action (65), the image processor (32) takes an image of the pallet (24) and the set down location. Action (66) sends the processed image to the algorithm (50). Algorithm response (54) sends the processed image to the server (36) with annotation that the processed image was taken when the pallet (24) is set down. The server actions (70) respond to the algorithm responses. For example, server responses (71) and (72) receive the pallet information from the algorithm. The server in (73) organizes corresponding pallet information and sends this information to the database. The server in (74) looks at the setting down processed image and determines from the location whether the pallet is in a designated storage location. If not, in (76) the pallet is flagged as an anomaly. Similarly in (75), the server determines from the lifting processed image if the pallet has an identifying tag. If not, in (76) this pallet is flagged as an anomaly. Thus a warehouse supervisor or worker can review any anomalies in the pallet storage system and get them fixed before the pallet is lost.

The actions and algorithm in FIG. 2 are repeated for as often as a given pallet is lifted and set down. For example, forklift operator may lift a first pallet, move it to another location to be set down, and the actions and algorithm responses described hereinabove occur. When the forklift approaches the designated storage location for the first pallet, the operator may find a second pallet already occupying the designated location. The forklift will set down the first pallet in a non-designated location, initially causing a flagged anomaly to occur from the server as described hereinbefore. The forklift may lift and move the second pallet which was occupying the first pallet's designated location. This picking up triggers the algorithm to direct the image processor to process images of this second pallet. The second pallet is set-down in a non-designated location, causing a flag on it location. The forklift now lifts and moves the first pallet into its designated location. These movement as recorded as described hereinbefore and the flag is removed as the first pallet is now in its designated location.

In another exemplary embodiment, the server is configured to organize annotated processed images such that corresponding pallet images can be viewed in chronological order. Thus the final disposition of any pallet can be instantly determined. The server is configured to send the organized annotated, processed images, including any flags, to the database.

In another exemplary embodiment, the system includes means to convert the organized annotated processed images and any flag information in the database into spreadsheet format. As known in the art, there are many software programs which can convert images and data into spreadsheet format.

In another exemplary embodiment of the invention, the algorithm (50) is part of the server (36).

The present invention also embraces a method of tracking an item on a pallet in a warehouse. FIGS. 3A and 3B depict a flowchart of the steps of the method according to the invention.

Referring to the FIGS. 3A and 3B, in an exemplary embodiment, the method comprises the steps of (101) selecting a pallet at a first location in the warehouse for movement, (102) lifting the pallet with a vehicle for lifting, moving, and setting down, (103) taking an image of the pallet and pick-up location, (104) sending the image of the pallet and first location with information that the pallet is being lifted to a server, (105) moving the pallet to a second location in the warehouse, (106) setting down the pallet in the second location, (107) taking an image of the pallet and the second location, (108) sending the image of the pallet and the second location with information that the pallet is set down to a server, (109) determining if the pallet has an identifying tag from the image of the pallet, (110) determining if the second location is a designated storage location, (111) identifying the pallet as an anomaly if the pallet has no identifying tag, (112) identifying the pallet as an anomaly if the second location is not a designated storage location, (113) storing the pallet image, location, pick-up and set-down information in a database, and (114) repeating the preceding steps (102)-(113) every time the pallet is moved.

In another exemplary embodiment of the method, the vehicle is a forklift truck and the (102) lifting step, (105) moving step, (106) setting down step are accomplished with the fork lift truck.

In another exemplary embodiment, the vehicle is provided with an image processor and a motion sensor. The image processor and motion sensor are communicatively linked to a first algorithm. The first algorithm is configured to direct the image processor to process images when the motion sensor indicates that the pallet is being lifted or set-down. The method further comprises the steps of (115) sensing the lifting of the pallet with the motion sensor simultaneously with the (102) lifting step, (116) communicating the lifting to the first algorithm, (117) directing the image processor to process an image of the pallet and the first location before the first (103) taking step, (119) sensing the setting down of the pallet with the motion sensor simultaneously with the (106) setting down step, (120) communicating the setting down to the first algorithm, (121) directing the image processor to process an image of the pallet and the second location before the second (107) taking step.

In another exemplary embodiment, the (109) and (110) determining steps are accomplished by a second algorithm in the server.

In another exemplary embodiment, the method further comprises the step (122) converting the pallet image information and location into a spreadsheet in the database.

In yet another exemplary embodiment, the identifying tag is a barcode. The image processor is provided with barcode scanning and decoding capability. The method further includes the step of (118) scanning and decoding the identifying tag code, and the first and second (104) and (108) sending steps include, sending the scanned barcode information to the server.

In another exemplary embodiment, the identifying tag is an alphanumeric code. The image processor is provided with alphanumeric scanning and decoding capability. The method further includes the step of (118) scanning and decoding the identifying tag code, and the first and second (104) and (108) sending steps include, sending the scanned barcode information to the server.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. 

The invention claimed is:
 1. A system for tracking an item on a pallet in a warehouse, comprising: at least one pallet; designated storage locations in the warehouse; a vehicle for lifting, moving, and setting down pallets; a motion sensor being provided on the vehicle, the motion sensor being wireless enabled and being capable of determining the lifting, moving and setting down of pallets, the motion sensor being configured to send lifting, moving, and setting down information when the motion sensor senses motion; an image processor provided on the vehicle, the image processor being wireless enabled, the image processor having a field of view capable of processing images of the pallet and the location of the pallet when the pallet is in contact with the vehicle; a server, the server being communicatively linked to the image processor and the motion sensor, the server having access to a database; an algorithm, the algorithm being communicatively linked to the motion sensor, the image processor, and the server, the algorithm being configured to direct the image processor to process images based on information received from the motion sensor about the pallet being lifted, being moved and being set down; the algorithm being further configured to receive processed images and to send the processed images with annotated motion sensor information to the server; the server being configured to organize the annotated processed images; and the server being further configured to identify and flag annotated processed images which show pallets without identifying tags and pallets which are not set down in designated storage locations.
 2. The system of claim 1, wherein the vehicle is a forklift truck.
 3. The system of claim 1, wherein the image processor and the motion sensor are one unit.
 4. The system of claim 1, wherein the designated locations are slot positions sized to fit a pallet and are identifiable by slot numbers.
 5. The system of claim 1, wherein the algorithm is configured to instruct the image processor to process an image when the motion sensor senses a pallet is lifted, moved, or set down.
 6. The system of claim 1, wherein the annotations are information about the pallet being lifted or being set down when the image was processed.
 7. The system of claim 1, wherein the server is configured to send the organized annotated processed images and any flags of annotated processed images to the database.
 8. The system of claim 7, further comprising means to convert the organized annotated processed images and any flags of annotated processed images in the database into spreadsheet format.
 9. The system of claim 1, wherein the pallet has an identifying tag.
 10. The system of claim 9, wherein the identifying tag is an alphanumeric code.
 11. The system of claim 10, wherein the image processor is configured to read and decode alphanumeric codes on the pallet and is configured to send decoded alphanumeric codes to the algorithm with the processed image.
 12. The system of claim 10, wherein the algorithm is configured to read and decode alphanumeric codes on the pallet in the processed images, and wherein the algorithm is configured to send decoded alphanumeric codes to the server with the processed images.
 13. A method of tracking an item on a pallet in a warehouse, comprising: selecting a pallet at a first location in the warehouse for movement; lifting the pallet with a vehicle for lifting, moving, and setting down; taking an image of the pallet and pick-up location; sending the image of the pallet and first location with information that the pallet is being lifted to a server; moving the pallet to a second location in the warehouse; setting down the pallet in the second location; taking an image of the pallet and the second location; sending the image of the pallet and the second location with information that the pallet is being set down to a server; determining if the pallet has an identifying tag from the image of the pallet; determining if the second location is a designated storage location; identifying the pallet as an anomaly if the pallet has no identifying tag; identifying the pallet as an anomaly if the second location is not a designated storage location; and storing the pallet image, location, pick-up, and set-down information in a database.
 14. The method of claim 13 wherein the vehicle is a fork lift truck, and the lifting step, the moving step, and the setting down step are accomplished with the fork lift truck.
 15. The method of claim 13, wherein the vehicle is provided with an image processor and a motion sensor, the image processor and motion sensor being communicatively linked to a first algorithm; the first algorithm being configured to direct the image processor to process images when the motion sensor indicates that the pallet is being lifted or set-down; the method further comprising the steps of: sensing the lifting of the pallet with the motion sensor simultaneously with the lifting step; communicating the lifting to the first algorithm; directing the image processor to process an image of the pallet and the first location before the first taking step; sensing the setting down of the pallet with the motion sensor simultaneously with the setting down step; communicating the setting down to the first algorithm; and directing the image processor to process an image of the pallet and the second location before the second taking step.
 16. The method of claim 13, wherein the determining steps and the identifying steps are accomplished by a second algorithm in the server.
 17. The method of claim 13, further comprising the step of: converting the pallet image information and location into a spreadsheet in the database.
 18. The method of claim 13, further comprising the step of repeating the preceding steps every time the pallet is moved.
 19. The method of claim 15, wherein the identifying tag is a barcode; the image processor being provided with barcode scanning and decoding capability; the method further comprising the step of scanning the barcode; and wherein the first and second sending steps include sending the scanned barcode information to the server.
 20. The method of claim 15, wherein the identifying tag is an alphanumeric code; the image processor being provided with alphanumeric code decoding capability; the method further comprising the step of scanning and decoding the alphanumeric code; and wherein the first and second sending steps include sending the decoded alphanumeric code to the server. 